3-D printed packaging

ABSTRACT

Items may be packaged for shipping or storage using additive manufacturing techniques, also known as three dimensional (3-D) printing. Packages made by such processes may be referred to as 3-D printed packages and may include packing material printed at least partially around the item(s) and/or an outer cover printed about at least a portion of an exterior of the packing material and/or the item(s). A packaging system may include a 3-D printer and a computing device communicatively coupled to the 3-D printer. The computing device may obtain a packaging model describing a package for one or more items. A print module of the computing device may include instructions to print the package at least partially about the item(s) according to the packaging model.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/887,973, filed Oct. 7, 2013, which is incorporated herein byreference.

BACKGROUND

Products are commonly packaged by a manufacturer or distributor prior tosale. This sort of packaging is referred to as “retail packaging.”Retail packaging varies widely depending on the products to be packaged,the size and the weight of the products, the durability or fragility ofthe products, where and how the products are to be sold, and numerousother factors. The retail packaging for a particular product is oftendesigned specifically for the particular product. Considerable time andexpense goes into designing retail packaging for a product. Due to thespecialized nature of retail packaging, the retail packaging for oneproduct is not likely to be suitable for another product. Thus, the costof designing retail packaging for a product significantly increases thecost of making the product available for sale. Such upfront design costsmay make retail packaging of some low volume or limited run productscost prohibitive.

Products and other items (collectively referred to as “items”) maysubsequently be packaged for storage and/or shipping. This sort ofpackaging is referred to as “non-retail packaging.” Non-retail packagingtypically employs general-purpose packaging supplies, such as cardboardboxes, bubble wrap, polystyrene peanuts, tissue paper, shrinkwrap,packing tape, and the like. Such general-purpose packaging supplies arereadily available, but are not particularly suited for the specificitems to be packaged. Consequently, items may be damaged during storageand/or transportation. Furthermore, the effectiveness of packaging isdependent largely on how the user chooses to package the item. Manyusers lack the skills or experience to effectively package items.

Accordingly, there remains a need for improved methods of retail andnon-retail packaging.

BRIEF DESCRIPTION OF DRAWINGS

The detailed description is set forth with reference to the accompanyingfigures. In the figures, the left-most digit(s) of a reference numberidentifies the figure in which the reference number first appears. Theuse of the same reference numbers in different figures indicates similaror identical items.

FIG. 1 is a schematic diagram of an example system usable to packageitems using 3-D printing.

FIGS. 2A-2D are schematic diagrams illustrating example packagingtechniques using 3-D printing.

FIGS. 3A-3F illustrate example 3-D printed packaging structures that maybe used to package items.

FIGS. 4A and 4B illustrate an example packaged item, packaged using 3-Dprinting.

FIG. 5 is a flowchart illustrating an example process of packaging anditem using 3-D printing.

FIGS. 6A-6D illustrate examples of arranging multiple 3D printedpackages.

DETAILED DESCRIPTION

This application describes using 3-D printing or other additivemanufacturing techniques for retail packaging (i.e., packaging of aproduct prior to sale by a manufacturer, distributor, or the like)and/or non-retail packaging (e.g., packaging for storage, shipping, orthe like). As used herein, the term non-retail packaging refers to anypackaging for storage and/or shipping, whether performed before or aftera sale to a consumer. That is, non-retail packaging includes shippingfrom a manufacturer to a customer, shipping from a manufacturer todistributor, shipping from a distributor to a customer, shipping fromany image individual to another, and/or packaging item(s) for storage.

In some instances, the techniques described herein may be used togenerate retail packaging for new products and/or existing products(e.g., repackaging of products with damaged or opened packaging, torefresh or update packaging, to package the product for a new ordifferent market, to add additional or alternative packaging features,etc.). The techniques described herein may additionally or alternativelybe used to generate non-retail packaging for products and other items(unpackaged items, items packaged using conventional retail packagingtechniques, and/or items packaged using the retail packaging techniquesdescribed herein). In some instances, the techniques described hereinmay be usable to generate packages that serve as both retail packagingand non-retail packaging. Additionally, in some examples, the techniquesdescribed herein may be used in conjunction with 3-D printing ofproducts themselves. For instance, after printing a product using 3-Dprinting techniques, a retail or non-retail package may then be printedfor the product. The package may be printed as part of a same printingoperation as the product itself, or as a separate printing operation inthe same or different printing area.

While many of the examples are described as using 3-D printing and/orbeing implemented by a 3-D printer, the techniques described herein arealso applicable to other forms of additive manufacturing. Unlessspecifically noted to the contrary, the terms “3-D printing” and “3-Dprinter” are used herein to mean additive manufacturing and additivemanufacturing machines, respectively.

Example 3-D Printed Packaging System

FIG. 1 illustrates a system 100 usable to implement 3-D printedpackaging of items. The system 100 may be used to provide retailpackaging for products that are for sale to consumers. The system 100may additionally or alternatively be used to provide non-retailpackaging for other items. In the case of non-retail packaging, theitems may or may not already include some packaging (e.g., retailpackaging).

As shown in FIG. 1, system 100 includes a computing device 102 incommunication with a 3-D printer 104. In the illustrated example, thesystem 100 also includes a scanner 106 and an item manipulator 108.However, in other examples, the scanner and/or manipulator may beomitted or combined with each other, the 3-D printer 104, and/orcomputing device 102. When present, the scanner 106 may comprise a 3-Doptical scanner, a 3-D laser scanner, and/or one or more cameras toobtain information about an item, such as its visual appearance, outerdimensions, or the like. Numerous different scanners are available, suchas, for example, the exaCT-s® CT Workstation or the Shapetracer LaserLine Scanner, both available from Wenzel America of Wixom, Mich., or theArtec Spikder, Artec L, or Artec EVA 3-D Scanners available from ArtecGroup of Palo Alto, Calif. In some examples, the scanner 106 mayadditionally or alternatively comprise an ultrasound scanner, an x-rayscanner, a spectrometer, a scale, and/or other scanning or sensingequipment to determine interior characteristics of the item, materialsfrom which the item is made, weight of the item, volume of the item,density of the item, and the like.

In some examples, the computing device 104 may “recognize” the itembased on the scan. The computing device 104 may recognize the item by,for example, reading a product identifier (e.g., universal product codeor “UPC”, model number, serial number, bar code, quick response code, orother identifier) of the item (if available), and then query a productcatalog, model store, or other database to obtain additional informationabout the item. The computing device 102 may additionally oralternatively recognize the item using object recognition (e.g., bycomparing the scan or a vector representation of the scan to a databaseof reference scans or images of items). Once an item is recognized, thecomputing device 104 may obtain additional information about the itemsuch as a computer model of the item, a textual description of the item,product reviews of the item, human input information about the item, webpages related to the item, or any other available information about theitem.

The item manipulator 108 may comprise a robotic arm or other computercontrolled manipulator. In some examples, the item manipulator 108 maybe specialized to move the item within the system 100. For instance, theitem manipulator 108 may include specialized hardware (e.g., itemengaging tools designed specifically for a particular type or shape ofitem) and/or software (e.g., customized code for a particular operationor set of operations). In that case the item manipulator 108 may becapable of limited and/or predetermined motions. However in otherexamples the item manipulator 108 may comprise a robotic arm with aconfigurable or articulatable item-engaging tool or other manipulatorhaving multiple degrees of freedom and capable of a wide range ofmotion. Numerous different manipulators are available depending on thespecific tasks to be performed. In one specific example, a six-axisrobotic arm, such as the Adapt Viper line of robotic arms available fromAdept Technology, Inc. of Pleasanton, Calif. In some embodiments, theitem manipulator 108 may additionally or alternatively comprise aconveyor belt, rollers, or other mechanisms to move items from onelocation and/or orientation to another.

The computing device 102, 3-D printer 104, scanner 106, and/or itemmanipulator 108 are in communication with one another over a wiredand/or wireless network. The network of system 100 may be furtherconnected to one or more other local and/or wide area networks, such asthe Internet.

When an item is received, the item may be placed in a scanning area 110,where the item may be scanned by the scanner 106 to determine the natureof the item. Once the item has been scanned and the system 100 hasdetermined the nature of the item to be packaged, the item may be movedto a printing area 112 where the item will be packaged. The item may bepackaged alone or with one or more other items (e.g., other items thatare part of a same order and/or are to be shipped to the same location).Once the item(s) are packaged, the packaged item(s) may be output to anoutput area 114 for storage, shipping, and/or further processing. Thefollowing description describes the process of packaging a single item.However, it should be understood that the process may also be used toprint packaging for/around multiple items.

The computing device 102 comprises one or more processors 116 and memory118. The processor(s) 116 may comprise one or more microprocessors(e.g., central processing units, graphics processing units, etc.), eachhaving one or more processing cores, one or more microcontrollers, orthe like. The memory 118 may be configured to store one or more softwareand/or firmware modules, which are executable by the processor(s) 116 toimplement various functions. While the modules are described herein asbeing software and/or firmware executable by one or more processors, inother embodiments, any or all of the modules or functional blocks may beimplemented in whole or in part by hardware (e.g., as an applicationspecific integrated circuit or “ASIC,” a specialized processing unit, afield programmable gate array or “FPGA,” etc.) to execute the describedfunctions. The memory 118 may comprise computer-readable media and/ordevices and may take the form of volatile memory, such as random accessmemory (RAM) and/or non-volatile memory, such as read only memory (ROM)or flash RAM. Computer-readable media includes volatile andnon-volatile, removable and non-removable media implemented in anymethod or technology for storage of information such ascomputer-readable instructions, data structures, program modules, orother data for execution by one or more processors or circuits of acomputing device. Examples of computer-readable media include, but arenot limited to, phase change memory (PRAM), static random-access memory(SRAM), dynamic random-access memory (DRAM), other types of randomaccess memory (RAM), read-only memory (ROM), electrically erasableprogrammable read-only memory (EEPROM), flash memory or other memorytechnology, compact disk read-only memory (CD-ROM), digital versatiledisks (DVD) or other optical storage, magnetic cassettes, magnetic tape,magnetic disk storage or other magnetic storage devices, or any othernon-transmission medium that can be used to store information for accessby a computing device. As defined herein, computer-readable mediaincludes hardware and does not include modulated data signals or carrierwaves.

Referring back to FIG. 1, the memory 118 includes a scanner module 120,a modeling module 122, a print module 124, and manipulator module 126,and a model store 128. The scanner module 120 may provide an interface(e.g., driver, application programming interface or “API,” or the like)to the scanner 106. For instance the scanner module 120 may providecommands to control the scanner 106 to obtain information about theitem. The scanner module 120 may additionally receive the output ofscanner 106 (i.e., the scanned image(s) or sensor data captured by thescanner 106). From the output of the scanner 106, the scanner module isable to generate an item model 130 (if one did not already exist) or mayselect and/or supplement an existing item model 130 (if one alreadyexists). Once generated, selected, and/or supplemented, the item model130 may be stored in the model store 128 or other repository forsubsequent access by local and/or remote computing devices.

The modeling module 122 generates a computer model of the packaging thatis to be applied to the item. In other words, the modeling module 122determines the geometry and layout of the package that should be used topackage the item, taking into account the item model 130. The modelingmodule 122 generates a packaging model 132 describing the geometrylayout of the package. The packaging model 132 may be stored in themodel store 128. While the item models and packaging models are bothshown as being stored in model store 128 in this example, in otherexamples the item models and packaging models may be stored separatelyin memory 118 or at one or more other data stores in communication withthe computing device 102. The modeling module 122 may be a stand alonemodule, or may be a part of, an add-on to, or may otherwise integratewith, a 3-D modeling program such as SolidWorks available from DassaultSystèmes SolidWorks Corp. of Waltham, Mass., Pro-Engineer available fromPTC of Needham, Mass., or the like.

Print module 124 may provide an interface (e.g., driver, applicationprogramming interface or “API,” or the like) between the computingdevice 102 and the 3-D printer 104. For example, the print module 124may include a printer driver and may provide commands controlling aprint head of the 3-D printer. Print module 124 may control the 3-Dprinter 104 to generate packaging for the item according to packagingmodel 132. The print module 124 may control, among other things, thematerial or materials from which the package is to be printed, printspeed of a print head of the 3-D printer 104, size and shape of packingmaterial and/or an outer surface or shell of the package.

The manipulator module 126 may provide an interface (e.g., driver,application programming interface or “API,” or the like) between thecomputing device 102 and the item manipulator 108. For example, themanipulator module 126 may be usable by the computing device 102 todirect the item manipulator 108 to move the item before, during and/orafter printing the package. For instance, the manipulator module 126 maydirect the item manipulator to place the item into the scanning area110, to rotate or otherwise move the object in the scanning area 110, tomove the object from the scanning area 110 into the printing area 112,to rotate or otherwise move the object in the printing area 112, and/orto remove the item from the printing area 112.

The computing device 102 also includes one or more network connections134 to connect the computing device 102 to the other devices in thesystem 100, as well as to one or more other local and/or wide areanetworks. In some examples, the network connections 134 may allow auser, such as a purchaser of an item, to specify how the item is to bepackaged for shipping to the purchaser or another intended recipient.

When the item is placed in the scanning area 110, the scanner 106 mayscan the item. From the scan, the computing device 102 may obtaininformation to determine the nature of the item from one or moresources. For instance, as discussed above, the computing device 102 mayrecognize the item based on a product identifier or based on objectrecognition. If the computing device 102 recognizes the item, thecomputing device 104 may query one or more data sources to obtainadditional information about the item. For instance, the computingdevice 102 may reference the model store 128 to determine whether or nota computer model of the item exists. If a computer model of the itemexists, the computing device 102 may reference an item model 130corresponding to the item to determine the geometry, materials, weight,volume, density, and/or other characteristics of the item. If a computermodel of the item is not available, the computing device 102 may scanthe item using scanner 106 to determine one or more characteristics ofthe item. In some instances the computing device 102 may have or be ableto obtain (e.g., through external resources via the Internet) a completeitem model 130 including exterior dimensions, interior dimensions,weight, volume, density, materials of construction, surface finish, andthe like. In other instances, the computing device 102 may have alimited or partial item model 130, which describes less than allcharacteristics of the item. For instance a limited or partial itemmodel might only include exterior dimensions of the item.

Based on item model 130 the item, modeling module 122 may construct orobtain (e.g., through external resources via a network such as theInternet) a packaging model 132 for the item. The modeling module 122may include a material palette 136 defining the materials that areavailable from which to construct a package for the item. The modelingmodule 122 may further include one or more packaging elements 138, suchas templates and previously stored design elements. For instance,packaging elements 138 may include computer models of ribs, flanges,honeycomb structures, bubble structures, trusses, or other designelements, features, or parts. The modeling module 122 may also include aphysics engine 140 to model forces that are likely to be applied byand/or to the item during storage, shipping, and/or sale. In oneexample, the physics engine 140 may take into account characteristics ofthe item (e.g., size, shape, weight, fragility/durability, etc.) basedon the item model 130, material properties (e.g., strength, elasticity,ductility, hardness, etc.) of the item and available packaging materialsfrom the material pallet 136, forces to which the item may be exposed(e.g., gravity, inertia, impact, air resistance, etc.), and/or otherfactors (e.g., price, scarcity, shipping mode, storage location,intended use, etc.) obtained from item catalogs, product reviews, websites, and/or other sources. In some instances, the physics engine 140may obtain such information for an item at least in part from a productidentifier of the item. The foregoing description is of just oneexample, and in other examples, the physics engine 140 and modelingmodule 122 may obtain information needed to perform their respectivefunctions directly or indirectly from the enumerated sources, or fromother available sources.

Based on the foregoing criteria, modeling module 122 may generate thepackaging model 132 customized for the item to withstand the forces thatare likely to be applied. For example, the physics engine 140 maydetermine that, based on a strength and weight of the item and adistance that the item is likely to be dropped during shipping, thepackaging should be able to withstand a certain impact force. In anotherexample, the physics engine 140 may determine that, based on thestrength and weight item and a number of items that are commonly stackedon top of one another, the packaging should be able to support a certainstatic load. In some examples, the physics engine 140 may employ finiteelement analysis (FEA) or other mathematical techniques to model staticand/or dynamic systems in which the item may be used/stored/shippedand/or the forces to which the item is likely to be exposed.

In other examples, instead of computing the forces to which the item islikely to be subjected, the physics engine 140 may categorize the iteminto one or more categories and may apply predetermined packaging rules,designs, or templates corresponding to the one or more categories. Forinstance, if the item has a density less than a certain threshold thephysics engine 140 may categorize the item as being a “light weight”item. The physics engine 140 may further categorize the item as being a“fragile” item if, for example, it has relatively thin spans ofmaterial, is made of a brittle or low strength material, or is for otherreasons susceptible to damage. The physics engine 140 may then identify(e.g., from a look up table or matrix) one or more packaging structuresto use for the item based on the categorizations of “light weight” and“fragile.” The physics engine may further modify or customize thepackaging structures based on, for example, the size, weight, or othercharacteristics of the item. For instance, the physics engine 140 maydetermine a packing structure or combination of packing structures(e.g., bubble and web structures in this example) to use to package anitem based on its categorization (e.g., “light weight” and “fragile”).The physics engine 140 may then adjust the number of packing structures(e.g., number of bubbles and/or webs, in this example), size ofpackaging structures (e.g., width, height, thickness, diameter, etc.),quantity of material used to generate the packing structures (e.g., massor volume), the material from which the packing structures areconstructed (e.g., hard plastic, elastomer, metal, etc.), and/or othercharacteristics of the packing structures (e.g., corner rounding,gussets, fillets, etc.) according to the characteristics of the item. Insome embodiments, the physics engine 140 may additionally oralternatively take into account the value of the item, constraints onthe cost of the package (e.g., what the customer is willing to pay),constraints on the size and/or weight of the package (e.g., due topostal or other delivery requirements), or other considerations.

Additional details of the packaging structures are described below inthe section entitled “Example Packing Structures.”

In some examples, before and/or after the item is placed in the printingarea 112, the item may have a release applied so that the 3-D printedpackaging does not stick to or damage the item. In one example, thecomputing device 102 may instruct the item manipulator to apply therelease to the item, while in other examples the release may be appliedto the item by another device or process prior to or after being placedin the printing area 112. In some examples, the release may comprise achemical or material (e.g., corn starch, wax, paper, metal foil, etc.)applied to item to prevent the 3-D printed packaging material fromadhering or bonding to the item. In other examples, the release maycomprise a property imparted to the item (e.g., an electrostatic charge,a polished surface finish, a cold temperature, electromagneticradiation, etc.) that helps to prevent the 3-D printed packagingmaterial from adhering or bonding to the item. In still other examples,the release may be omitted (e.g., if the 3-D printed packaging materialdoes not adhere to the material of the item, if a gap is maintainedbetween the item and the 3-D printed packaging material during printing,and/or if it is desired that the 3-D printed packaging material adhereor bond to the item). In still other examples, a release may be appliedto some parts of an item but not other parts, such as limited corners oredge points of the item to allow the package to adhere to, or form aweak bond with, the item (e.g., to secure the package to the item duringshipping). In such an example, the limited corners or edge points thatare not coated with the release may be sized and positioned such thatthe adhesion or weak bonds may be easily broken upon opening the packageto separate the item from the package. The release may be appliedbefore, during, or (in the case where part of the package is printedbefore the item is placed in the printing area) after the printingprocess commences.

Once the packaging model 132 has been generated and the item isotherwise ready for packaging (e.g., any desired release has beenapplied, any other items that are to be packaged with the item arepresent, etc.), the computing device 102 may initiate the printingprocess. In some examples, the item may be placed in the printing area112 before printing commences and the package may be printed around theitem. In other examples, at least a portion of a package may be printedbefore the item is placed in the printing area 112. For instance, thecomputing device 102 may instruct the 3-D printer 104 (e.g., via printmodule 124) to print a bottom or side surface and/or one or more supportstructures of a package prior to instructing the item manipulator 108(e.g., via the manipulator module 126) to place the item into theprinting area 112. The item manipulator 108 may then place the iteminto/onto the partially printed package (e.g., onto already printedsupport structures and/or into an already partially printed shell of apackage), the computing device 102 may then cause the 3-D printer 104 toprint the remainder of the package around the item.

In some examples, the package printed by the printing process may be onecontinuous part. In that case, the package may completely encapsulatethe item or may cover only part of the item. In the case that thepackage encapsulates the item, the package may provide an air and/orwater tight package. In some examples, the package may be hermeticallysealed. Because the package is 3-D printed, the package may be seamless,minimizing chances that the package will catch on surfaces it comes intocontact with and consequently minimizing the chances of damage to thepackage or the surfaces with which it comes into contact. The seamlesssurfaces of the package may also improve material handling capabilities.For instance, the seamless surfaces of the package may make the packageeasier to slide on conveyors, easier to pick up (e.g., with suctiondevices or grippers), easier to stack and load, etc. The seamlessappearance may also provide a clean, aesthetically appealing appearance.

In other examples, the package maybe printed as multiple parts tofacilitate opening or unpackaging the item. For instance, the packagemay comprise multiple parts that fit together like a 3-D puzzle and/orare held in place by one or more other parts. Additionally oralternatively, the package may include one or more opening features tohelp assist in the opening of the package. By way of example and notlimitation, the package may include one or more thinned or frangibleregions where the package is configured to separate during opening, oneor more tabs or finger holds configured to be grasped by a user, or thelike.

The package may additionally or alternatively include one or more of thefollowing features:

-   -   thermal insulation (e.g., regions of material having a low        coefficient of thermal conductivity such as wood, polystyrene,        cellulose or glass fiber insulation, air or other gasses, and/or        a vacuum) and/or electrical insulation (e.g., dielectric        material);    -   vibration damping (e.g., regions of viscoelastic material such        as rubber, silicone, synthetic polymers, wood, or composites        including any of the foregoing);    -   crumple zones (e.g., features designed to fail before the rest        of the package) to absorb energy of impacts;    -   child safety features (e.g., features requiring more strength,        instruction reading ability, and/or dexterity to open than a        typical child possesses);    -   tamper resistant and/or tamper evident features (e.g., features        that will clearly show once the package has been opened or        tampered with, such as for example, 2-D or 3-D water marks,        frangible regions that will break if tampered with, materials or        indicators that change color or otherwise indicate when they are        exposed to air or humidity, ink or dye in the package that if        punctured will discolor the package indicating the tampering);    -   desiccant material (e.g., received in pockets, pouches, or        receptacles printed in the package and/or the package itself may        be printed in whole or in part of a desiccant material);    -   all or part of the package may form an accessory for the item        (e.g., a charging stand for an electronic device, a cover for an        electronic device, a pill holder for medication, etc.); and/or    -   the package may be made in whole or in part of a recyclable        material (e.g., thermoplastic, glass, metal, ceramic, etc.),        biodegradable material (e.g., cellulose based materials, sand        with organic binder such as glycerin, etc.), and/or water        soluble material (e.g., sucrose, glycerin, corn starch, gelatin,        etc.) such that the entire package may be recycled and/or        disposed of without any subsequent sorting or separating.

During or after 3-D printing the package structure, one or more piecesof information may be printed onto the package. The information mayinclude, for example, shipping information (e.g., sender and/orrecipient address), postage for the package, a packing list of theitem(s) in the package, shipping instructions (e.g., “fragile”, “thisend up,” etc.), opening instructions, set up or assembly instructions,“quick-start instructions,” description of features of the package(e.g., child safety, desiccant, etc.), warning labels (e.g., hazardousmaterials), a list of materials from which the package is constructed, apackaging license (e.g., “by opening this package you agree to be boundby the terms . . . ”), a machine readable code (e.g., quick responsecode, bar code, 3-D relief code, or the like), a date on which thepackage was printed, a location at which the package was printed, anentity that printed the package, an identifier of the printer thatprinted the package, or any other pertinent information. The informationmay be printed in 2-D or 3-D by the 3-D printer 104 or by a 2-D printerlocated in or proximate the printing area 112.

Hybrid 3-D Printed/Conventional Packaging

In some examples, 3-D printed packaging may be combined with one or moreconventional packaging techniques to result in one or more hybridtechniques. In one example, the package may comprise a preprinted orpreformed container, such as a cardboard box. A 3-D printed package orportion of a 3-D printed package (e.g., packing material) may be placedin or printed and the preprinted or preformed container. For instance,in one simple example 3-D printed packing material may be printed aroundan item, the item enclosed in the packing material may then be placedinside the preformed container. Alternatively, the preformed containermay be placed in the printing area 112, a portion of packing materialmay be printed within the container, and item may be placed in thecontainer and the partially printed packing material, and a remainingportion of the packing material may be printed around the item withinthe container.

In another example, a conventionally packaged item may further have a3-D printed package printed around the conventional package. Forinstance, an item may be packaged in conventional packing materials suchas bubble wrap, tissue paper, or the like and/or may be placed in aconventional container such as a cardboard box. The conventionallywrapped item may then be placed into the printing area 112, and a 3-Dprinted package including a shell and/or packing material may be printedaround the conventionally packaged item.

Example Packing Structures

As discussed above, structure of package may be based upon the fragilityof the item, the weight of the item, the shipping distance, shippingmode, and/or the value of the item. For instance, fragile items may bepackaged with a more protective structure of packing material thansturdy items. Heavy items may be packaged with a more robust structureof packing material than light weight items. The shipping distance,shipping mode, and value of the item may also be taken into account,with further distances and higher values resulting in more robustpacking structures than shorter distances and lower values. Likewise,certain shipping modes (e.g., freight, bulk rate, etc.) may result inmore robust packing than others (e.g., airmail, courier, drone, etc.).The robustness of a package may be adjusted by adjusting one or more ofthe type of support structure (e.g., lattice structure, a honeycombstructure, a truss structure, a bubble structure, one or more supportribs, web structure, loose particles or fibers, etc.), quantity ofpacking material (e.g., volume, mass, thickness, etc.), material usedfor packing material (e.g., plastic, rubber, silicone, silicon, glass,metal, stone, composites of any of the foregoing, etc.), and/orcharacteristics of the packing material (e.g., strength of material,hardness, toughness, elasticity, vibration damping ability, thermalinsulating ability, etc.).

Multiple different packing materials and/or support structures may beused to package the item. For example, different support structuresand/or crumple zones may be used in different portions of the package.For example, a relatively hard and/or rigid inner support structure maybe formed immediately around (e.g., directly surrounding) the item,while a softer and/or more flexible material may be formed around theinner support structure, or vice versa.

FIGS. 2A-2D illustrate example packaging techniques, FIGS. 3A-3Fillustrate example packaging structures, and FIGS. 4A and 4B illustratean example packaged item using packaging techniques and packagingstructures such as those shown in FIGS. 2A-2D and FIGS. 3A-3F. However,numerous other packaging techniques and structures are possible withinthe scope of this disclosure by combining, rearranging, modifying,and/or omitting aspects of these and other examples described herein.The examples herein are merely examples for the purpose of illustration.

FIG. 2A illustrates an example in which an item 200 is packaged in afirst example package 202A. The item 200 may represent any item that isto be packaged (retail packaging, non-retail packaging, or both). By wayof example and not limitation, the item 200 may represent an item thatis to be packaged for sale in a brick and mortar store, an item that isto be packaged for sale via an online merchant, an item to be placed instorage (e.g., long or short term storage), or an item that is to beshipped. Specific examples of items that may be packaged using thesetechniques are too numerous to list. A few arbitrary examples mayinclude electronic devices, consumer products, medical devices,medication, food, etc.

The package 202A in this example completely surrounds or encapsulatesthe item 200, and includes packing material 204A that completelysurrounds the item 200, and an outer cover or shell 206A disposed aroundan exterior of the packing material 204A. The packing material 204A maycomprise a lattice structure, a honeycomb structure, a truss structure,a bubble structure, a web structure, one or more support ribs, looseparticles or fibers, and/or other structures that may support the item200 in the package 202A. Furthermore, the packing material 204A maycomprise any of the materials described herein. The specific supportstructure(s) and/or material(s) used may depend on the desired strength,strength-to-weight ratio, density, rigidity, flexibility, vibrationdamping, impact absorption, thermal and/or electrical insulation, orother characteristics of the package 202A. In some examples, the size,material, and/or other characteristics of the package 202A may be basedat least in part on a weight, durability, and/or cost of the item 200.

In the example of FIG. 2A, the packing material 204A is shown as beingsubstantially homogenous throughout the package 202A. However, in otherexamples, the packing material may be heterogeneous (e.g., includingmultiple distinct areas of different support structures and/or differentpacking materials). Also, while the package 202A is shown as having onlya single region of packing material 204A and a single shell 206A, inother examples packages may include multiple packing materials and/orregions of packing materials, and/or multiple outer covers or shells. Inone specific example, a first portion of the packing material 204A(e.g., a region proximate to the item 200) may be printed of a desiccantmaterial, such as silica, activated charcoal, calcium sulfate, calciumchloride, and molecular sieves, rice, or the like, while a secondportion of the packing material 204A is made of a non-desiccantmaterial. In other examples, the packing material 204A may be madeentirely of desiccant material. In either of the foregoing examples, thesecond portion of the packing material 204A and/or the shell 206 mayform a seal (e.g., hermetic seal) around the item 200 and the firstportion of the packing material 204A comprising the desiccant material.Furthermore, in other examples, packages may omit either the packingmaterial or the shell, or may employ a composite packing/shell, whichmay be homogenous or heterogeneous.

In some embodiments, a volume occupied by the packing material 204A mayhave a lower density than a volume occupied by the shell 206A. This maybe accomplished by structural and/or material differences between thepacking material 204A and the shell 206A. In some examples, this may beaccomplished by making the packing material 204A porous and/or includingvoids, cavities, pouches, or “bubbles,” while the making the shell 206Aof a solid and/or non-porous material. In that case, the packingmaterial 204A may be made of the same or different material than theshell 206A. The pores, voids, cavities, pouches, and/or bubbles may befilled with air or other gas, or may be substantially empty space (e.g.,vacuums or partial vacuums). In some examples, a region defined by thepacking material 204A may include about 30% to 70% by volume of air,gas, and/or substantially empty space. In other examples, the regiondefined by the packing material 204A may include 70% or more by volumeof air, gas, and/or substantially empty space. Additionally oralternatively, this difference in density between the packing material204A and the shell 206A may be accomplished by making the packingmaterial 204A of a lower density material (e.g., plastic, polystyrene,etc.) than the shell 206A (e.g., metal, higher density plastic, etc.).

FIG. 2B illustrates another example in which the item 200 is packaged ina second example package 202B. In this example, the package 202Bincludes multiple regions of packing materials 204A and 204B andmultiple shells 206A and 206B. Like the example of FIG. 2A, the package202B completely encapsulates the item 200. However, in this example, thepackage 202B includes packing material 204A and additional or secondpacking material 204B. The additional packing material 204B in thisexample is localized at one or more limited locations around the item200 and does not encapsulate the item. The additional packing material204B may be located at locations of the item that may benefit fromadditional strength, impact absorption, or other protection. In theillustrated example, the additional packing material 204B is disposed atcorners of the item 200. However, in other examples, the additionalpacking material 204B may be disposed at other locations relative to theitem 200. The additional packing material 204B may have differentconstruction (e.g., different structure) and/or be made of differentmaterial than the packing material 204A and/or the shells 206A and 206B.In one specific example, the additional packing material 204B may bemade of a material (e.g., a viscoelastic material) and/or having astructure (e.g., an accordion or bubble structure) having greaterdamping ability than the packing material 204A (e.g., a truss, lattice,or honeycomb structure) to dampen vibrations and/or absorb impactsimparted to the package 202B and minimize their transmission to the item200. Additionally or alternatively, in some examples, the additionalpacking material 204B may comprise a desiccant material to absorbmoisture from within an interior of the package.

Also in this example, the package 202B includes an outer shell 206Bdisposed around shell 206A. The shells 206A and 206B may be made of thesame or different material and may have the same or differentstructures. In one example, the outer shell 206B may be made of a harderor more rigid material than the shell 206A. Additionally oralternatively, the shell 206A may be made of a material that is moreflexible, deformable, and/or has a greater damping ability than theouter shell 206B, thereby further isolating the item 200 from vibrationsor impacts imparted to the exterior of the package 202B.

Also, in this embodiment, the item 200 is disposed in the package 202Boff-center. The location of the item 200 within the package 202A may bechosen based on a center of gravity of the item, a relative durabilityof the different portions of the item, or the like. For instance, in theexample of FIG. 2B, the item 200 may be disposed toward the bottom leftof the package 202B based on the item 200 having a center of gravitylocated at the top right corner of the item 200, such that the center ofgravity of the item 200 is located near a center of the package 202B.Additionally or alternatively, the item 200 may be disposed toward thebottom left of the package 202B based on the item 200 having a fragileregion on the top right of the item 200, thereby providing a largerregion of packing material between the fragile region of the item andthe outside of the package 202B.

FIG. 2C illustrates an example package 202C in which the packingmaterial and shell are formed integrally as a single packing shell 208.The packing shell 208 may comprise a uniform material throughout or, asshown in FIG. 2C, may be variable over its volume. In some examples, oneor more material characteristics of the packing shell 208 may varyacross one or more dimensions of the package 202C. For instance, thepacking shell 208 may be printed with a higher density (in materialand/or structure) proximate the item 200, with the density decreasingtoward an exterior of the package 202C, or vice versa (i.e., low densitynear the item and higher density at the exterior of the package). Thedensity of the packing shell 202 may change based on, for example, adistance from the item 200, or a relative distance between the item 200and the exterior of the package 202C. The variability in material and/ormaterial characteristics may smoothly transition at a uniform rate, maysmoothly transition one or more variable rates, may transition indiscrete steps, or a combination of the foregoing. Additionally oralternatively, the packaging structure of the packing shell 208 maychange abruptly or smoothly transition, such as from an outer honeycombconfiguration to an inner lattice work configuration.

FIG. 2D illustrates another example package 202D in which the package202D covers less than the entire item 200. In this example, the item 200protrudes at least partially from the package 202D. This example may beused where, for example, the item 200 has a base or stand to support theitem 200 during use. In that case, once delivered, the package 202D maybe placed with the base of the item resting on the ground or othersupport surface and the package 202D may be removed from the item 200without having to lift the item from the package 202D.

FIGS. 3A-3F illustrate examples of several structures that may be usedfor packing materials, shells, and/or other portions of packagesaccording to this application. However, packages according to thisdisclosure are not limited to these example structures. The structuresmay be printed from any one or more of the materials described herein orother materials.

FIG. 3A illustrates an example honeycomb structure that may be used topackage items. The size, shape, wall thickness, and othercharacteristics of the honeycomb structure may vary depending on theitem to be packaged and the requirements and constraints on the package.Such a honeycomb structure is an example that may provide a relativelyhigh rigidity in at least one dimension with relatively highstrength-to-weight ratio.

FIG. 3B illustrates an example web structure comprising multiplerelatively fine fibers or strands that connect to each other, otherportions of a package, and/or an item to be packaged.

FIG. 3C illustrates example structures in which one or more supportribs, flanges, or gussets are disposed between one or more portions of apackage (e.g., between top, bottom, sides of the package, internalfeatures, and/or other support structures of the package) and/or theitem. The rib structures may be employed to increase one or moreradiuses, add structural supports at weak locations, and/or removestress risers in the package.

FIG. 3D illustrates an example lattice structure in which elongatedbars, rods or other supports are arranged to form trusses. The bars,rods or supports may be disposed, for example, between (i) one or moreportions of a package (e.g., top, bottom, sides, internal features,and/or support structures of the package), (ii) one or more nodes orconnection points of the lattice structure, and/or (iii) the item.

FIG. 3E illustrates an example hybrid honeycomb-web structure in whichweb structures are formed in a honeycomb pattern. The honeycomb patternmay be uniform, or as illustrated in FIG. 3E, may vary in size, shape,and/or web cross section. In one example, the hybrid honeycomb-webstructure may be created or obtained through operation of the physicsengine 140 (FIG. 1) or other portion of the system 100.

FIG. 3F illustrates an example packing structure comprising multipleloose or fibrous particles, similar to packing peanuts or silly string.The loose or fibrous particles may comprise any desired shape and/orsize. In some examples, the particles may be configured to interlock,frictionally engage, and/or entangle with one another. In otherexamples, individual particles may be sized and/or shaped to provideresilience, vibration damping, impact absorption, or the like.

Another example support structure includes a bubble or air pocketstructure in which a relatively thin membrane of material is printed toform bubbles or air pockets. The bubbles or air pockets may be uniformin size, shape, and/or wall thickness or may vary in size, shape, and/orwall thickness. In some examples, the bubbles or air pockets may beindividually sealed, while in other examples, some or all of the bubblesor air pockets may be in communication with one or more other of thebubbles or air pockets via one or more air passages. In the latter case,the air passages may be sized to restrict passage of air, thus providinga damping effect to damp vibration and/or absorb impact. The size of theair passages may be uniform throughout, or may be varied to restrictairflow more in some areas than others.

Yet another example support structure includes a sponge-like structurehaving a plurality of voids or pores. The voids or pores may be uniformin size and/or shape, or may be variable. Moreover, the voids may beevenly spaced throughout the sponge structure, or may be non-uniformlyspaced throughout the sponge structure.

Any of the foregoing structures may be modified and/or combined witheach other or other structures to produce packages according to thisdisclosure. By way of example and not limitation, the honeycombstructure of FIG. 3A may be modified to include gussets or cornerrounding between adjacent chambers of the honeycomb to further increasea structural integrity and minimize stress risers in the structure.

FIGS. 4A and 4B illustrate an example packaged item 400 comprising apackage 402 encapsulating an item 404. In the illustrated example, theitem is shown as a cup or mug for ease of explanation. However, in otherexamples, the item may be any item that is to be packaged (e.g., forstorage or shipping). In FIG. 4A, the item 404 is shown in broken linesinside the package 402. FIG. 4B is a cross sectional view of thepackaged item 400 taken along line B-B in FIG. 4A. As shown in FIG. 4B,the package 402 may include a shell 406 covering an exterior of thepackage 402, and multiple regions of packing material 408, 410, 412, and414. Each of the different regions 408, 410, 412, and 414 of packingmaterial may have a different structure, a different density, and/or bemade of a different material. The structure and/or material of thedifferent regions of packing material may be chosen based oncharacteristics (e.g., size, density, durability, strength, material ofconstruction, etc.) of different regions or parts (e.g., interior,exterior, top, bottom, void, protrusion, etc.) of the item to beshipped. Further, the structure and/or material of the different regionsof packing material may be chosen based on one or more constraints(e.g., weight of the package, total weight of the packaged item,expected orientation of travel, size of the overall package or one ormore dimensions, etc.).

For instance, in the illustrated example, the bottom packing material408 and the top packing material 410 may comprise a flexible ordeformable material and may have a bubble or sponge structure configuredto dampen vibration and/or absorb impacts applied to the packaged item400. In the illustrated example, the bottom packing material 408 and thetop packing material 410 are two separate pieces of material that may bepulled apart to access the item 404 once the shell 406 is removed. Thebottom packing material 408 and the top packing material 410 may be madeof the same or different materials. The packing material 412 disposedaround the handle of the mug is an example of packing material that maybe used to protect fragile regions of the item 404. In this example, thepacking material 412 may comprise a relatively hard material having arelatively rigid structure (e.g., lattice, truss, or rib structures)that supports and protects the fragile portion (the handle in thisexample) of the item. In some examples, the packing material 412 maycomprise multiple parts that fit together around the fragile part andare separable to remove the packing material 412 once the package 402 isopened. The packing material 414 within a cavity of the item (thereservoir of the mug in this example) may be made of yet anothermaterial and/or structure designed to provide a relatively rigidsupporting structure (e.g., honeycomb) to prevent the item from beingcrushed when exposed to outside forces.

The package 402 may also include one or more printed opening mechanismsto facilitate opening the package. In this example, the openingmechanism includes a tear strip 416 disposed around at least a portionof a perimeter of the package 402 outside the packing material 408, 410,412, and 414, but within the shell 406. The tear strip 416 may be madeof a material having strength greater than a material of the shell 406.Additionally or alternatively, the shell 406 may include a frangiblefeature or other region aligned with the tear strip 416 to facilitatetearing or breaking of the shell 406 along the frangible seam or region.The frangible feature may comprise, for example, one or moreperforations, thinned or weakened areas, and/or notches or grooves. Inthe illustrated example, the tear strip 416 protrudes through the shell406 and includes a pull tab 418 or other graspable member. In such anexample, a user may grasp the pull tab 418 and pull the tear strip 416to tear or otherwise break the shell 406. Once the shell 406 is broken,it may be removed and the user may pull apart the top and bottom packingmaterials 408 and 410 to expose the item 404. The packing materials 412and 414 may then be removed from the item.

In other examples, the tear strip 416 may not protrude from the shell406. In that case, the package may include a visual indicator of how thepackage is to be opened. For instance, the package may have a dashedline printed on an exterior of the package where the tear strip islocated, a picture showing a person opening the package, and/or textualinstructions for how to open the package.

Additionally, in some embodiments, the opening mechanism may comprise achild resistant opening mechanism that is readily operable by an adult,but is difficult or impossible to open by a child. In one example, achild resistant opening mechanism may be implemented using the tearstrip shown in FIG. 4B by making the tearing force required to pull thetab 418 at or above a threshold force requiring more strength to openthan a typical child possesses. The tearing force may be set at or abovethe threshold by, for example, selecting a thickness and/or material ofthe shell to provide the threshold force.

Example Packaging Process

FIG. 5 is a flowchart showing an example process 500 of packaging anitem in whole or in part using 3-D printing or additive manufacturing.The process 500 may, but need not necessarily, be implemented in wholeor in part by the system 100. The process 500 is described withreference to the system 100 for ease of understanding, but is notlimited to being performed with the system 100. Accordingly, the system100 is capable of performing numerous other processes and the process500 may be implemented using numerous other systems.

The process 500 is illustrated as collections of blocks and/or arrows inlogical flowcharts representing a sequence of operations that can beimplemented in hardware, software, firmware, or a combination thereof.The order in which the blocks are described is not intended to beconstrued as a limitation, and any number of the described operationscan be combined in any order to implement the process, or alternateprocesses. Additionally, individual operations may be omitted from theprocess without departing from the spirit and scope of the subjectmatter described herein. In the context of software, the blocksrepresent computer instructions that, when executed by one or moreprocessors, perform the recited operations. Such instructions may beresident in memory (e.g., memory 118 of FIG. 1). In the context ofhardware, the blocks may represent one or more circuits (e.g., ASICs,FPGAs, specialized processors, or the like) configured to execute therecited operations.

The example process 500 includes, at block 502, determining one or morecharacteristics of one or more items to be packaged. The characteristicsmay include any measurable or observable property of the item such as,for example, geometry (internal and/or external), size, shape,materials, weight, volume, density, color, hardness, strength, surfacefinish, temperature, chemical composition, or the like. Thecharacteristic(s) of the item may be determined in a variety of ways. Byway of example and not limitation, characteristics of each item may bedetermined by referencing a computer model for the item (block 504),scanning the item (block 506), and/or receiving human input describingthe item (block 508). Any or all of these operations, or otheroperations, may be used to determine characteristics of the item(s) tobe packaged.

At block 504, characteristics of the item may be determined byreferencing a computer model of the item (if available) or otherinformation about the item. For example, a computing device, such ascomputing device 102, may refer to a computer model of the item, such asitem model 130. The item model maybe stored locally at the computingdevice, or stored remotely and accessible by the computing device via anetwork (e.g., a local or wide area network). In some examples a usermay specifically provide or identify the item model that the computingdevice is to reference for a given item (e.g., by uploading, selecting,or otherwise identifying the item model). In other examples, thecomputing device may automatically identify an item model correspondingto the item in response to recognizing the item. In various examples,the computing device may recognize the item by one or more of opticalrecognition of the item (e.g., by comparison of an image of the itemwith a catalog or potential items, such as items in an inventory),scanning an item identifier (e.g., bar code, quick response code, radiofrequency identification tag, etc.), or the like. In some instances, theitem model may include only dimensional information of the item, whilein other instances the item model may include information aboutmaterials, manufacturing techniques, surface finishes, and otherinformation about the item.

At block 506, characteristics of the item may be determined by scanningthe item. For example, a computing device, such as computing device 102,may obtain scan information from a scanner, such as scanner 106. In someexamples, the computing device may control the scanner or otherwisecause the scanner to scan each item, while in other examples, thescanner may scan each item independently of the computing device and maymake the scan information available to the computing device (e.g., bystoring the scan information in a model store such as model store 128,by pushing the scan information to the computing device, or by allowingthe computing device to query the scanner to obtain the computingdevice). As noted above, the scanner 106 may comprise a 3-D opticalscanner, a 3-D laser scanner, one or more cameras to determine outerdimensions of the item, an ultrasound scanner, an x-ray scanner, aspectrometer, a scale, and/or other scanning or sensing equipment todetermine interior characteristics of the item, materials from which theitem is made, weight of the item, volume of the item, density of theitem, and the like. These scanned characteristics of the item may beobtained and/or used in addition to or instead of characteristicsdetermined from the item model (if available). For instance, in someexamples, the scanned characteristics may be used to supplement an itemmodel (e.g., to provide material information, weight, density, or thelike to supplement an item model that only includes geometricinformation of the item). Further, as noted above, some scannedcharacteristics may be used to recognize the item in order to identifyan item model corresponding to the item. In still further examples, thescanned characteristics may be used to generate an item model for anitem for which an item model was not previously available.

At block 508, human input may be used to determine characteristics ofthe item. The human input may be preexisting information (e.g., productspecifications, item descriptions, brochures, websites, etc.) describingthe item. Additionally or alternatively, the human input may begenerated substantially at the time the item is to be packaged (e.g., byan operator of the computing device, scanner, or 3-D printer inputting adescription of one or more characteristics of the item). In yet anotherexample, human input may be obtained from one or more remote human usersby, for example searching for customer reviews of the item (e.g., on oneor more merchant web sites or the internet), requesting human users todescribe the item (e.g., requesting information about the item via amechanical Turk service), or the like.

The method 500 may further include, at block 510, preparing a printingarea for the item(s). Preparing the printing area may include cleaningthe printing area following a previous printing operation, manipulatingone or more other objects (e.g., items or packages) in the printing area(block 512), and/or printing a portion of a package to receive the item(block 514). In some instances, manipulating the one or more otherobjects, at block 512, may simply comprise removing a package from aprevious printing operation. In other instances, multiple items may besequentially packaged in the printing area. In that case, manipulatingone or more other objects at block 512 may comprise placing a pallet,tray, or other support surface into the printing area, rearranging orreorienting a support surface previously placed in the printing area,and/or moving or reorienting one or more packaged items in the printingarea. In one specific example, multiple items may be sequentiallypackaged in situ on a pallet or other support surface. Once the supportsurface is fully loaded, the support surface may be removed from theprinting area along with the multiple packaged items supported thereon.

As noted, in some examples, preparing the printing area may comprise, atblock 514, printing a portion of a package for the item. The portion ofthe package printed may depend on the nature of the item to be packagedand may include, for example, a base, sidewall, receptacle, one or moresupports, or the like. In one simple example, a base or bottom of apackage may be printed in the printing area on which the item may beplaced. For instance, referring to the example of FIG. 4B above, abottom portion of the shell 406 and packing material 408 may be printedin the printing area as part of preparing the printing area to receivethe item 404.

Additionally or alternatively, the method 500 may include, at block 516,preparing the item to be packaged. In some instances the item may notrequire any special preparation prior to printing. However, in otherexamples, at block 518 a release may be applied to the item to preventthe packaging material from adhering to or damaging the item. In oneexample, a computing device such as the computing device 102 mayinstruct a tool such as item manipulator 108 to apply the release to theitem, while in other examples the release may be applied to the item byanother device or process prior to or after being placed in the printingarea. In some examples, the release may comprise a chemical or material(e.g., corn starch, wax, paper, metal foil, etc.) applied to item toprevent the 3-D printed packaging material from adhering or bonding tothe item. In other examples, the release may comprise a propertyimparted to the item (e.g., an electrostatic charge, a polished surfacefinish, a cold temperature, electromagnetic radiation, etc.) that helpsto prevent the 3-D printed packaging material from adhering or bondingto the item. In still other examples, the release may be omitted (e.g.,if the 3-D printed packaging material does not adhere to the material ofthe item, if a gap is maintained between the item and the 3-D printedpackaging material during printing, and/or if it is desired that the 3-Dprinted packaging material adhere or bond to the item). As noted above,the release may be applied before, during, or (in the case where part ofthe package is printed before the item is placed in the printing area)after the printing process commences.

While the foregoing examples describe operations to facilitate thepackaging process, the item may additionally or alternatively besubjected to one or more other operations in preparation to be packaged.For instance, the item may be sanitized (e.g., by chemical sanitizer,steam, irradiation, or other sanitation mechanisms), be subjected to apreserving process, coated with a moisture barrier, or any number ofother processes depending on the item to be packaged.

At block 520, the item maybe placed and/or supported in the printingarea and, at block 522, printing of the package around the item(s) maycommence or continue (in the case where the package was partiallyprinted prior to the item being placed in the printing area). In someexamples, the item(s) or partially printed package may be manipulatedduring the printing process. For instance, in one simple example, anitem may be placed in the printing area, a top portion of a package maybe printed around the item, the package may then be rotated 180 degreesto expose the bottom of the item, and the bottom portion of the package(now oriented on the top) may then be printed. In other examples, theitem may remain stationary during the printing process and one or moreprint heads of the 3-D printer may move around the item. In that case,one or more surfaces or members supporting the item may move to maintainsupport of the item while accommodating movement of the print head(s) ofthe 3-D printer. As noted above, in some examples, the printing processmay include printing one or more packages around one or more itemssimultaneously and/or sequentially.

Once one or more packages have been printed, at block 524, informationmay be printed on the package in 2-D or 3-D. The information may beprinted on the package(s) by the same 3-D print head(s) used to printthe package(s) or by a separate 2-D printer located in or proximate theprinting area. A wide range of information may be printed on thepackage(s). By way of example and not limitation, information that maybe printed on the package(s) includes shipping information (e.g., senderand/or recipient address), packing list of the item(s) in the package,shipping instructions (e.g., “fragile”, “this end up,” etc.), openinginstructions, description of features of the package (e.g., childsafety, desiccant, etc.), warning labels (e.g., hazardous materials), alist of materials from which the package is constructed, a packaginglicense (e.g., “by opening this package you agree to be bound by theterms . . . ”), a machine readable code (e.g., quick response code, barcode, 3-D relief code, or the like), a date on which the package wasprinted, a location at which the package was printed, an entity thatprinted the package, an identifier of the printer that printed thepackage, marketing or advertising information, an aesthetic design orimage (e.g., printed on wrapping paper), or any other pertinentinformation.

At block 526, the package(s) may be output. As noted above, outputtingthe package may comprise outputting a single package containing one ormore items or outputting multiple packages (e.g., on a pallet or othersupport surface) each containing one or more items. In one example, acomputing device such as computing device 102 may instruct a tool suchas manipulator 108 to remove the packaged item(s) from the print area.In other examples, the packaged items may be output from the printingarea by one or more other systems in coordination with or independent ofthe computing device.

Multiple Package Examples

As discussed above, in some examples, multiple items may be packagedconcurrently or sequentially. In the case where the items are to bepackaged in multiple packages, the size, shape, and configuration of oneor more of the packages may be based at least in part on the size,shape, and configuration of others of the multiple packages. Forinstance, if multiple packages are to be placed on a pallet or othersupport surface, the size, shape, and/or configuration of some or all ofthe packages may be chosen at least in part to result in a uniform,well-packed unit of packages. A uniform, well-packed unit of packages isone that is stable (i.e., won't topple over) and is substantially freeof voids, gaps, and open spaces between packages. However, uniform,well-packed unit of packages need not be completely free of voids, gaps,and open spaces. For instance, a uniform, well-packed unit of packagesmay include voids, gaps, and open spaces to provide clearance to fithands or package handling tools between packages, to provide clearancefor assembly or disassembly of packages to/from the unit of packages, toallow for expansion or contraction of the packages, or the like. In someexamples, a uniform, well-packed unit of packages may be substantiallycube shaped or rectangular prism shaped. However, in other examples, auniform, well-packed unit of packages may take on other shapes. FIGS.6A-6D are top or cross-sectional views of examples of uniform,well-packed units of packages.

In some examples, all of the packages making up the unit of packages maybe configured based at least in part the other packages in the unit ofpackages. In other examples, a limited number of the packages (e.g., asingle package, corner packages, a row of packages, etc.) in the unit ofpackages may be configured based in part on a remaining space on apallet or other support surface. In that case, size and shape of thelimited number of packages may be modified (relative to the otherwiseoptimal size and shape for the package) to fill a remaining space on apallet or other support surface (or a row of stacked packages) to resultin a uniform, well packed unit of packages. In either of the foregoingexamples, the computing device 102 may take into account the size andshape of multiple packages in a queue of packages to be printed whencreating new package models. Furthermore, as new packages are added tothe queue, the computing device 102 may modify or adjust the size andshape of one or more other packages in the queue in order to create auniform, well-packed unit of packages.

In some examples, such as those shown in FIGS. 6B-6D, the packagesmaking up the unit of packages may include one or more interlockingfeatures configured to interlock with adjacent packages on the top,bottom, and/or sides to hold the unit of packages together. Examples ofinterlocking features include, without limitation, protrusions, grooves,puzzle pieces, channels, ridges, notches, or the like. FIG. 6Billustrates an example in which some packages have bulbous protrusionsthat slide into complimentary grooves in adjacent packages to lock thepackages together. FIG. 6C illustrates an example in which some packagesinclude outwardly beveled protrusions (e.g., male dovetails) that fitinto complimentary beveled channels (e.g., female dovetails) in adjacentpackages to lock the packages together. In other examples, such as theexample shown in FIG. 6D, the packages themselves may be configured aspuzzle pieces that lock together with one or more other packages.Additionally or alternatively, one or more straps, bands, wraps,supports, or other structures may be printed around at least a portionof the unit of packages to secure the unit of packages together and/orto the pallet or support surface. FIG. 6A illustrates a band or strap602 surrounding a unit of packages. Similar bands or straps may also beprovided around the circumference of the unit of packages in otherdimensions (e.g., when viewed from the front and/or side). In someexamples, multiple bands or straps may be used in each dimension (e.g.,one band or strap around each row and/or column of packages). In someexamples, such bands or straps may be applied using conventionalstrapping techniques. However, in other examples, the bands and/orstraps may be printed directly around the unit of packages during orafter a process of printing the packages making up the unit of packages.The bands or straps may be made of plastic, metal, paper, and/or anyother material suitable and/or conventionally used for strappingpurposes.

By taking into account characteristics of other items to be packaged, acomputing device such as computing device 102, may ensure that not onlyis each item well packaged, but also that the packages will fit togetherwith the other items to create a unit of packages that can easily betransported and/or stored together. Additionally, the packages may beadded to a pallet or other transport structure in an order that protectsmore fragile and/or expensive items (e.g., fragile and/or expensiveitems may be placed at or near a top of a stack of packages). In onespecific example, multiple items all destined for a same destination(e.g., city, transfer station, warehouse, etc.) may all be packagedconcurrently or sequentially) and placed on a pallet or other supportsurface for transfer to the destination.

Alternatively, the packages making up the unit of packages may beindependently packaged (i.e., not taking into account the other packagesin the unit of packages and/or without knowledge of what unit ofpackages the package will be a part of). In that case, a computingdevice, such as computing device 102, may determine, for a plurality ofpackages, how to stack and arrange them on one or more pallets or othersupport surfaces to provide the most uniform, well packed unit(s) ofpackages possible. In some examples, the computing device may furtherprint one or more spacers or empty packages to fill gaps or voids in theunit of packages to improve a stability and/or uniformity of the unit ofpackages. In some examples, the computing device may direct an itemmanipulator, such as item manipulator 108, to stack the packages as thecomputing device directs. However, in other examples, the itemmanipulator may be programmed to stack the packages independently of thecomputing device. In some instances, the item manipulator may use touchsensors on the item manipulator to determine the size and shape of thepackages and to place them accordingly. In other examples, the itemmanipulator may use input from a scanner, such as scanner 106, or one ormore other cameras or sensors to determine the size and shape of thepackages and to place them accordingly.

In yet another example, multiple items may be packaged in multipleregions or compartments of a single package. Each region or compartmentmay include a single item or multiple items designed for a samedestination. The package may include one or more separation features toallow separation of each of the multiple compartments or regions fromthe rest of the package. By way of example and not limitation, each ofthe regions or compartments may be coupled to the package by a skin orone or more thin strips of material, and one or more tear strips may beprovided between the regions or compartments to separate the regions orcompartments. Each region or compartment may be separated from the restof the package by pulling on or otherwise breaking respective tearstrips to separate the respective region or compartment into a separatepackage. In some examples, pulling a single tear strip may separatemultiple regions or compartments (e.g., a whole row or column ofpackages) from the package. Examples of other separation featuresinclude perforations, notches, thinned or weakened sections, or thelike.

Example Packaging Station

In one example, a 3-D printing system such as that shown in FIG. 1 maybe implemented as a packaging station. Such a station may be located ina bricks and mortar store, such as a retail store or shipping store(e.g., FedEx Kinkos, UPS Store, etc.), a governmental building (e.g., apost office), an airport, an indoor or outdoor kiosk, a storagefacility, or at any other suitable location where items are to bepackaged for shipping or storage. In this example, the system mayinclude a user terminal including a display and one or more inputdevices (e.g., a microphone, touch screen, mouse, keyboard, etc.). Theuser may identify one or more items to be packaged by, for example,placing the item(s) in the printing area or another area proximateand/or associated with the 3-D printing system, selecting the items froma catalog or menu of items, notifying a clerk or operator of the items,or the like. In another example, the user may have previously identifiedthe item(s) from a remote terminal (e.g., a personal computer, mobiledevice, or the like).

Additionally, in some examples, the user may be prompted or otherwiseallowed to input additional information, such as a purpose of thepackaging (e.g., storage, shipping, etc.), a sender address, a recipientaddress, a shipping mode and/or speed (e.g., UPS ground, FedExovernight, etc.), any special handling instructions (e.g., fragile,hazardous materials, etc.), a cost of the item(s), an exteriordecoration or “wrapping,” and/or one or more package features (e.g.,thermal insulation, vibration damping, hermetically sealed, child safe,tamper evident, etc.). In other examples, the packing station mayautomatically determine or infer any or all of these types of additionalinformation. Additionally, in some examples, the 3-D printing system maydisplay a price for packaging and/or shipping the item, and provide aninterface by which the user can pay for the packaging, storage, and/orshipping.

Regardless of how the items are identified to the 3-D printing system,the item(s) may be packaged according to the method of FIG. 5 or anyother processes described herein. In some implementations, the packageditem(s) may be automatically placed into storage and/or shipped withoutany further input from the user. For instance, the packages may beplaced in a post-printing staging area for pickup by a common carrier(e.g., USPS, UPS, FedEx, or the like), transported to a carrier forshipping, and/or loaded onto a vehicle (e.g., truck, airplane, ship,drone, etc.) for shipping. Alternatively, the packages may be placed inan output area for pickup and storage and/or shipping by the user. Invarious examples, the item(s) may be purchased prior to, as part of, orafter the 3-D packaging process. In one specific example, the user maygo to a store, select one or more items they want to purchase, providethe item(s) to the 3-D packaging system, and have the item packagedand/or shipped.

Ecommerce Merchant Example

In another example, a 3-D printing system including some or all of thecomponents and/or techniques shown and described herein, with or withoutother components, may be implemented by an ecommerce merchant. Such asystem may be located in a warehouse or fulfillment center of theecommerce merchant and may utilize any or all of the structures,techniques, and systems described herein. When a user places an orderfor one or more items, the one or more items may be provided to the 3-Dprinting system. In some examples, the items may be retrieved by anemployee, robot, conveyor, and/or other inventory management systems ortools of the ecommerce merchant and placed in the printing area oranother proximate or associated area (e.g., a staging area, a bin ofitems to be packaged, or the like). In other examples, the items may beretrieved automatically by and/or under the control of one or moreautomated systems (e.g., robots, conveyors, machines, computer systems,etc.) and made available to the 3-D printing system. In some examples,the 3-D printing system may be communicatively coupled to the one ormore automated systems.

In this example, once the user purchases one or more items from theecommerce merchant, the item(s) may be automatically packaged and/orshipped according to the method of FIG. 5 or any other processesdescribed herein.

Example 3-D Printed Packaging for Medication

While the examples above are generally applicable to packaging of anyitems, the following example describes details suitable for packagingpharmaceutical compositions, medications, vitamins, supplements, and thelike. This example may employ a 3-D printing system and/or techniquessuch as that shown and described herein. In this example, however, thesystem may be located in a sterile environment.

In some examples, one or more pills, capsules, gelcaps, or othermedicinal product may be packaged in a 3-D printed package according toaccording to the method of FIG. 5 or any other processes describedherein. In such an example, the operation of preparing the printing areamay comprise sterilizing the printing area. Further, the 3-D printedpackage in such an example may include one or more tamper evidentfeatures and/or child safety features, such as those described above. Insome examples, the container may be formed and the medicinal product maybe counted and placed in the container. In other examples, the medicinalproduct may be placed in the printing are and the container may beformed around the medicinal product. Such an arrangement may allow for awide variety of new and previously unattainable packaging solutions. Insome examples, the container may comprise a bottle, pouch, or otherpackage into which individual pills, capsules, gelcaps, or other dosesof the medicinal product are placed. In that case, the container may bemade of a conventional plastic, metal, ceramic, or other materialcommonly used to house medicinal products.

In other examples, the 3-D printed container may comprise an ingestiblecapsule to hold a medicinal product in powder, liquid, solid, or gelform.

In still other examples, the medicinal product itself may be printed bythe 3-D printing system. For instance, a print media of the 3-D printingsystem may comprise a pharmaceutical composition. In that case, the 3-Dprinter used in the system may be a food or pharmaceutical or food grade3-D printer configured to print using pharmaceutical and/or food gradeprint media, such as compositions including, for example, one or moreactive ingredients with or without one or more fillers (e.g., lactose,cellulose, corn starch, sugars, whey, yeast, etc.) and/or one or morebinders (e.g., povidone, xanthan gum, carbopol, glycerine, polylacticacid, etc.), or the like. Individual pills, capsules, gelcaps, or otherdoses (collectively referred to as “pills”) of medicinal product may beformed (e.g., printed) in any desired shape and size, customized for aparticular user's dose, and/or may be printed directly into a container.The container itself may additionally or alternatively have been printedusing the same or different 3-D printing system. Formulation of printmedia may be varied during print process to adjust concentration ofactive and/or inactive ingredient in different pills and/or in differentparts of a single pill (e.g., high concentration in exterior of pill forquick acting with lower concentration in interior of pill for longlasting). Print media may additionally or alternatively be varied tochange the density and/or solubility of different portions of the pill(e.g., lower density and/or higher solubility of a first portion topromote quick release of active ingredient, with higher density and/orlower solubility of a second portion to promote delayed release).Additionally or alternatively, the formulation of the print media may bevaried to use different active and/or inactive ingredients in differentpills and/or different portions of a single pill (e.g., different activeingredients in different portions of the pill). Color of the print mediamay also be varied in accordance with variations in formulation in orderto visually indicate the changes in formulation. These variances inprint media may be designed as multiple (e.g., 2, 3, 4, . . . n)discrete portions, or the variances may be continuously variable (e.g.,the concentration, density, and/or solubility of the print media maygradually increase from a minimum to a maximum).

The foregoing examples may be used to produce and/or package medicationas-needed or on-demand. As such, the examples may find use in a staffedor self service pharmacy, hospital, doctor's office, grocery store, in apatient's home, or the like. Moreover, the examples may be applicable tobricks and mortar locations as well as online or mail order providers.

What is claimed is:
 1. A method of packaging an item, the methodcomprising: supporting an item in a printing area of a three dimensional(3-D) printer; and printing a package at least partially around the itemin the printing area of the 3-D printer, wherein printing the packagecomprises: printing packing material around the item; and printing anouter cover about an exterior of the packing material.
 2. The method ofclaim 1, further comprising printing a shipping address directly ontothe package in the printing area of the 3-D printer.
 3. The method ofclaim 1, wherein printing the package at least partially around the itemcomprises printing the package completely around the item, such that theitem is encapsulated within the package.
 4. The method of claim 3,wherein the package is seamless and hermetically seals the item.
 5. Themethod of claim 1, wherein the package is suitable for shipping bycommon carrier.
 6. The method of claim 1, wherein printing the packingmaterial comprises printing at least one of a lattice structure, ahoneycomb structure, a truss structure, a bubble structure, a webstructure, or one or more support ribs.
 7. The method of claim 1,wherein at least one of a size or material of the packing material isbased at least in part on a weight of the item.
 8. The method of claim1, wherein a region occupied by the packing material has a lower densitythan a region occupied by the outer cover.
 9. The method of claim 1,wherein the packing material and the outer cover are printed of a samematerial.
 10. The method of claim 1, wherein the packing material isprinted of a first material and the outer cover is printed of a secondmaterial, different than the first material.
 11. The method of claim 1,further comprising printing at least a portion of the package of adesiccant material.
 12. The method of claim 1, further comprisingsupporting multiple items in the printing area of the 3-D printer; andprinting the package at least partially around the multiple items in theprinting area of the 3-D printer.
 13. The method of claim 1, whereinprinting the package comprises printing at least one of: an openingmechanism into the package and usable to open the package; or a tamperevident feature into or onto the package.
 14. The method of claim 1,further comprising printing a portion of the package prior to supportingthe item in the printing area, and wherein supporting the item in theprinting area comprises supporting the item on the portion of thepackage printed prior to supporting the item.
 15. The method of claim 1,further comprising, prior to printing the package: scanning the itemwith a scanner to obtain information about the item; receiving theinformation about the item from the scanner; generating a model of theitem based the information about the item received from the scanner; andgenerating a packaging model based at least in part on the model of theitem, wherein the printing the package is performed based at least inpart on the packaging model.
 16. The method of claim 15, wherein: thescanning the item comprises determining a weight of the item; thegenerating the of the packaging model is further based on the weight ofthe item, such that the package is based at least in part on the weightof the item.
 17. A method of further packaging a packaged item forshipping, the method comprising: supporting the packaged item in aprinting area of a three dimensional (3-D) printer, the packaged itembeing packaged in retail packaging; and printing a non-retail package atleast partially around the packaged item in the printing area of the 3-Dprinter.
 18. The method of claim 17, wherein printing the non-retailpackage comprises: printing packing material around the packaged item;and printing an outer cover about an exterior of the packing material.19. The method of claim 18, wherein printing the packing materialcomprises printing at least one of a lattice structure, a honeycombstructure, a truss structure, a bubble structure, a web structure, orone or more support ribs.
 20. The method of claim 18, wherein a regionoccupied by the packing material has a lower density than a regionoccupied by the outer cover.
 21. A method of packaging an item, themethod comprising: supporting an item in a printing area of a threedimensional (3-D) printer; scanning the item to determine: dimensions ofthe item; and weight of the item; generating a packaging model based onthe dimensions of the item and the weight of the item; and printing,based on the packaging model, a package at least partially around theitem in the printing area of the 3-D printer.
 22. A method of packagingan item, the method comprising: supporting an item in a printing area ofa three dimensional (3-D) printer; scanning the item with a scanner toobtain information about the item; receiving the information about theitem from the scanner; generating a model of the item based theinformation about the item received from the scanner; generating apackaging model based at least in part on the model of the item; andprinting a package at least partially around the item in the printingarea of the 3-D printer, wherein the printing the package is performedbased at least in part on the packaging model.
 23. The method of claim22, wherein: the scanning the item comprises determining a weight of theitem; the generating the of the packaging model is further based on theweight of the item, such that the package is based at least in part onthe weight of the item.
 24. The method of claim 23, wherein printing thepackage at least partially around the item comprises: printing packingmaterial around the item; and printing an outer cover about an exteriorof the packing material.
 25. The method of claim 24, wherein at leastone of a size or material of the packing material is based at least inpart on the weight of the item.